Highway construction



June 16, J E RCE 2,044,498

HIGHWAY CONSTRUCTION Filed June 10, 1955 2 sneets-sne e t 1 INVENTOR, Zfa J Pea/c ATTORNEYS.

June 16, 1936. j EA E 2,044,498

. HIGHWAY CONSTRUCTION Filed June 10, 1955 2 Sheets-Sheet 2 INVENTOR, Zea J Pea/"ca ATTORNEYS.

Patented June 16, 1936 HIGHWAY CONSTRUCTION Leo J. Pearce, Olathe, Kans., assigncr of one-half to Lloyd M. Chambers, Olathe, Kans.

Application June 10, 1935, Serial No. 25,843

18 Claims.

This invention relates to highway construction and has particular reference to that type of road which comprises an upper or wearing surface of a rigid cementitious substance commonly called concrete highway and the primary object of this invention is to provide improvements in such a road as will prolong its life by way of preserving the rigid cementitious superstructure because of the ability of the elements in the construction to relieve the upper rigid superstructure of stresses and strains to which it is otherwise sub jected when the highway is in use.

One of the important aims of this invention is to provide a highway construction which comprises a number of specially formed and uniquely combined courses, one of which is a pillow-course made up of comminuted material such as sand, gravel or other analogous substance which may be packed or spread to suit conditions, said pillowcourse being encased in a suitable envelope or enclosure that is made up of pre-formed sheet material such as heavy paper.

Another object of this invention is the provision of unique and novel means of combining a pillow-course in a highway construction which means includes a case for the pilow-course that may have parts to completely enclose the sand or like material or which may have only members at the longitudinal edges of the highway which serve to confine the pilow-course to a position beneath the rigid cementitious superstructure.

,A large number of minor objects which include the unique way of securing together the various parts of the pillow-course case and the novel manner of associating the sheet material with the highway construction will appear during the course of the following specification referring to the accompanying drawings wherein one preferred embodiment of the invention has been illustrated and wherein modifications of the preferred form have been shown.

In the drawings,

Figure 1 is a vertical cross section through a highway constructionmade to embody the present invention.

Fig. 2 is a fragmentary top plan view of a section of the highway construction, parts being broken away for clearness.

Fig. 3 is an enlarged fragmentary detailed sectional view taken on line III-III of Fig. 2 and illustrating the unique expansion joint which is used in highway construction when the same is made to embody the present invention.

Fig. 4 is an enlarged fragmentary detailed sectional view through one side .of the highway construction taken on line IV-IV of Fig. 2.

Fig. 5 is a greatly enlarged fragmentary detailed sectional view taken through the anchor which is employed in one form of the invention.

Fig. 6 is a similar View to that shown in Fig. 4 and illustrates a modified form of the invention.

Fig. 7 is a view similar to that of Fig. 6 and shows a still further modification of highway construction, and

Fig. 8 is a vertical cross section through a highway construction which embodies an even further modification of the invention.

Reference to Figs. 1 to 5 inclusive will readily indicate that the highway construction consists essentially of the conventional form rails I!) that extend along the longitudinal sides of the highway construction and upon the subgrade l2 that has been prepared by grading, rolling, or otherwise conditioning so that it will properly receive the component parts of the highway per se. After forms have beenplaced, the pillow-course is laid upon subgrade l2 therebetween. This pillow-course in the form illustrated in Figs. 1 to inclusive, comprises a continuous lower sheet l4 and an upper or cover sheet 16 positioned in the relation shown in Fig. 1. Each of these sheets are substantially continuous but comprises a number of over-lapping strips of heavy paper or the like that extend transversely across the highway con- Struction so that the portions thereof adjacent the ends are in over-lapped relation. In the instance shown in Figs. 1 and 4, lower sheet I4 is extended up along the sides of the pillowcourse and then inwardly along the top thereof so that the upper cover sheets 16 will Over-lap for seourement thereto.

The means of securing together the upper and lower sheets 14 and I6 is preferably in the form of a suitable anchor which will not become dislodged after once moved to the operative position. This anchor is shown in Figs. 4 and 5 and may consist of a specially formed nail-like structure having a shank l8 and a head 20 with a pair of pivotally mounted wings 22 thereon which, when outward, upward movement is im parted to the anchor after it has been forced to position, will move outwardly to the positions shown in Figs. 4 and 5 so that the anchor cannot be withdrawn.

The pillow-course has a'filling of sand .or other suitable comminuted material .24 that may be compacted to a suitable density as the said course is laid. Sand has been found highly satisfactory and when it is used a decided cushion effect is presented to the overlying concrete slab 26 that is poured upon the pillow-course in the regular fashion. This upper rigid cementitious superstructure 26 is in the form of a series of sections which have their adjoining ends in substantially abutting relation to form expansion joints detailed in Fig. 3. This expansion joint should consist of a filling of asphalt 28 that is poured into the space between the ends of sections of superstructure 25 and in order to insure longitudinal movement when contraction and expansion occurs, a friction plate 30 is placed beneath superstructure 26 so that it laps the proximal ends of these aforesaid sections. One section of the superstructure 26 is secured to the friction plate 3i! as at 32 through the medium of a number of pins or the like whilethe immediately adjoining section merely rests upon plate 30 so that it will freely move. Plate 30 is depressed into the pillow-course so that its upper face is on the same plane with the upper face of said pillowcourse and the lower face of the superstructure 26. This is another important feature of the invention and the employment of a pillow-course as mentioned, will permit such relationship between the parts. In thepreferred embodiment of the invention, this pillow-course is of uniform thickness throughout and after rails ID are removed, the case, which is formed as before mentioned, is strong enough to confine the comminuted material 24 until the shoulders are graded and compacted. Thereafter, the pillow-course is definitely confined and it will serve to equalize pressure, absorb shocks and otherwise function in serving as a preserving course for the rigid superstructure 2B.

In some instances it may be desirable to eliminate the continuous upper sheet of material which forms a part of the case for the pillowcourse and the side walls of the pillow-course may be strengthened when eliminating such upper sheet as shown in the modified embodiment of the invention illustrated in Fig. 6. When constructing the highway in accordance with this modified form of the invention, rails 40 are placed upon the subgrade 42 in the usual fashion and then the several strips of road paper or the like, are extended transversely across the subgrade 42 in over-lapping relation. In so laying the paper, a bottom sheet 44 is created and a length of the paper is rebent upon itself adjacent the ends so that a wall 46 of double thickness is made. A portion of the material is turned in between filling 48 and superstructure 5i! and this inturned portion is likewise made up of two thicknesses of the paper. The end of the paper is disposed between subgrade 42 and layer 44 as illustrated at 52 so that it will be definitely secured. It is desirable in this form of the invention to anchor the inturned double thickness portion of the pillow-course sheet to the superstructure 5t and a number of anchor members 54 in the form of nail-like units may be employed. When they are employed, the heads thereof should be confined between the upper and lower layer of the double thickness portion which is confined between filling 48 and superstructure 50. Obviously when rail 40 is removed, the paper cannot become dislodged and the shoulder is graded and compacted as before.

In the form of the invention shown in Fig. 7, rail 60 is upon subgrade 62 in the usual manner and the paper encasing filling M is formed as illustrated. The lower sheet 66 is rebent upon itself to form an inturned portion 68 and a side wall 10 both of which are double thickness. The upper sheet 12 extends in over-lapping relation with the double thickness inturned portion 68 and an anchor 74, having its head between the two thicknesses of the inturned portion 68 is projected through upper sheet 12. and into filling 64. Obviously the manner of creating this double thickness side wall is susceptible of establishinga very strong and rigid construction that will not become disassembled when rail is removed and the shoulders are being formed. The upper superstructure I6 is laid upon the pi]- low-course in the regular manner.

Reference to Fig. 8 indicates a manner of associating a pillow-course with a highway con- 'struction without the employment of the road paper. In this instance, side rails 80 are placed upon the subgrade 82 and longitudinally extending plates 84 are driven into the subgrade and allowed to overlap rails 88 as illustrated in the u left of Fig. 8. inturned flanges 86 formed on plates 84 are embedded in the rigid cementitious superstructure 88 after the concrete is poured. However, prior to the pouring of the concrete,

the comminuted material 90 is laid upon subgrade 82. After the concrete has been poured, rails 89 may be removed and a shoulder 92 graded and compacted in the regular manner. Obviously plates 84 will confine the sand or comminuted material 9H during this shoulder formthe strips forming the pillow-course casing in any suitable manner.

In some forms of construction, the rails or analogous members Iii need not be as high as the combined thickness of the laminated paving. The subgrade may be channeled out to receive the entire pillow-course including the case and filling.

From the foregoing it will be observed that the important component parts of a highway construction embodying this invention include a well prepared subgrade, a pillow-course of comminuted material properly confined, and a rigid superstructure of cementitious material. A number of Ways of forming this unique and novel highway construction have been illustrated and described and it is obvious that other ways of making the highway construction might be employed without departing from the spirit of the invention or scope of the appended claims.

Having thus described the invention, what I claim as new and desire to secure by Letters Patent is:

1. A highway construction comprising a subgrade; a pillow-course of shiftable material and of uniform thickness overlying the subgrade; and a rigid cementitious superstructure resting upon the said pillow-course. p

2. A highway construction comprising a subgrade; ,a pillow-course of shiftable material and of uniform thickness overlying the subgrade; a case enclosing the pillow-course; and a rigid cementitious superstructure resting upon the said pillow-course.

3. A highway construction comprising a subgrade; a pillow-course of shiftable material and of uniform thickness overlying the suhgrade, a rare-formed sheet of "material overlying the said pillow-course; and .a rigid cementitious superstructure resting :upon said sheet and pillowcourse.

4. A highway construction comprising a subgrade; a pillow-course of sand :of uniform thickness overlying the subgrade; a sheet of material interposed between the .subgrade and pillowcourse extending-upwardly along the sides of said pillow-course to confine the material thereof; and a rigid cementitious superstructure resting upon said pillow-course.

5. A highway construction comprising a 3111b? grade; a pillow-course of sand of uniform thickness overlying the subgrade; a sheet of material interposed between the subgrade and pillowcourse to confine the material thereof; and a rigid cementitious superstructure resting upon said pillow-course; said sheet -of vmate-rial extending inwardly from the longitudinal edges of the pillow-course and superstructure and between the two whereby to hold the longitudinal marginal portions of the pillow-course against displacement.

6. A highway construction comprising a subgrade; a pillow-course of comminuted material and of uniform thickness overlying the subgrade; a rigid cementitious superstructure resting upon said pillow-course; and a case for said pillowcourse comprising a sheet of heavy paper, disposed between the subgrade and pillow-course, having upturned portions along the sides of said course and inturned margins extending between the pillow-course and superstructure, and another sheet of heavy paper disposed between the said pillow-course and superstructure, overlapping and secured to the intur-ned margins of the said first mentioned sheet.

7. A highway construction comprising a subgrade; a pi-How-course of comminuted material and of uniform thickness overlying the subgrade; a rigid cementitious superstructure resting upon said pillow-course; and a case for said pillowcourse comprising a sheet of heavy paper, disposed between the subgrade andpillow-course, having upturned portions along the sides of said course and i-nturnedmargins extending between the pillow-course and superstructure, and another sheet of heavy paper disposed between the said pillow-.

course and superstructure, overlapping and secured to the inturned margins of the said first mentioned sheet; the means of securement between said overlapping sheets of heavy paper being anchored in the comminuted material of the said pillow-course.

8. A highway construction comprising a subgrade; a pillow-course of comminuted material and of uniform thickness overlying the subgrade; a rigid cementitious superstructure resting upon said pillow-course; and .a case for said pillow-course comprising a sheet of heavy paper, disposed between the subgrade and pillow-course, having upturned portions along the sides of said course and inturned margins extending between the pillow-course and superstructure, and another sheet of heavy paper disposed between the said pillow-course and superstructure, overlapping and secured to the inturned margins of the said first mentioned sheet, the means of securement between said overlapping sheets of heavy paper extending through the latter and having portions thereof anchored in both the comminuted material of the said pillow-course and in the said superstructure.

"9. A highway construction comprising a subgrade; a pillow-course comminuted material overlying the subgrade; a rigid cementitious superstructure resting uponthe pillow-course and a sheet af material disposed between the subgrade and pillow-course extending upwardly along the sides thereof and inwardly between the superstructure and pillow-course, said sheet of material being rebent upon itself along the inwardly and the upwardly extending portions thereof to form a double thickness side wall for the said pillow-course.

. 10. A highway construction comprising a subgrade; at pillow-course comminuted material overlying the subgrade; a rigid cementitious superstructure resting upon the pillow-course and a sheet of material disposed between the subgrade and pillow-course extending upwardly along the ides thereof and inwardly between the superstructure and pillow-course, said sheet of material being rebent upon itself along the inwardly and the upwardly extending portions thereof to form a double thickness side wall for the said pillowcourse; the edge of said material extending inwardly between the subgrade and sheet of material to anchor the same in place.

11. A highway construction comprising a subgrade; a pillow-course comminuted material overlying the subgrade; a .rigid cementitious superstructure resting upon the pillow-course and a sheet of material disposed between the subgrade and pillow-course extending upwardly along the sides thereof and inwardly between the superstructure and pillow-course, said sheet of material being rebent upon itself along the inwardly r.

and the upwardly extending portions thereof to form a double thickness side wall for the said pillow-course, the portion of said sheet of material extending inwardly between the pillow-course and rigid superstructure having an anchor extending upwardly into the said superstructure.

12. A highway construction comprising a subgrade; a pillow-course comminuted material over-- lying the subgrade; a rigid cementitious superstructure resting upon the pillow-course .and a rial being rebent upon itself along the inwardly and the upwardly extending portions thereof to form a double thickness side wall for the said pillow-course, the rebent portion of said sheet of material extending between the pillow-course and rigid superstructure having an anchor extending upwardly through the uppermost layer of material into the said superstructure.

13. A highway construction comprising a subgrade; a pillow-course comminuted material overlying the subgrade; a rigid cementitious superstructure resting upon the pillow-course and a sheet of material disposed between the subgrade and pillow-course extending upwardl along the sides thereof and inwardly between the superstructure and pillow-course, said sheet of material being rebent upon itself along the inwardly and the upwardly extending portions thereof to form a double thickness side wall for the said pillow-course, the rebent portion of said sheet of material extending between the pillow-course and rigid superstructure having an anchor extending upwardly through the uppermost layer of material into the said superstructure, said anchor having a head disposed between the two layers of said sheet material whereby to preclude sinking into the said pillow-course as the superstructure is poured.

14. A highway construction comprising a subgrade; a pillow-course comminuted material overlying the subgrade; a rigid cementitioussuperstructure resting upon the pillow-course; a sheet of material disposed between the subgrade and pillow-course extending upwardly along the sides thereof and inwardly between the superstructure and pillow-course; and a sheet of material disposed between the pillow-course and superstructure overlapping the portion of the first mentioned sheet disposed between the superstructure and pillow-course, said first mentioned sheet being rebent upon itself along the inwardly and the upwardly extending portions thereof to form a double thickness wall for the said pillow-course.

15. A highway construction comprising a sub grade; a pillow-course of comminuted material overlying the subgrade; a rigid cementitious superstructure resting upon the pillow-course; a sheet of material disposed between the subgrade and pillow-course extending upwardly along the sides thereof and inwardly between the superstructure and pillow-course; and a sheet of material disposed between the pillow-course and superstructure overlapping the portion of the first mentioned sheet disposed between the superstructure and pillow-course, said first mentioned sheet being rebent upon itself along the inwardly and the upwardly extending portions thereof to form a double thickness wall for the said pillowcourse, said overlapping sheet materials having an anchor extending through one thickness of the rebent sheet and through the other sheet into the said comminuted material of the pillowcourse.

16. A highway construction comprising a subgrade; a pillow-course of comminuted material overlying the subgrade; a rigid cementitions superstructure resting upon the pillow-course; a sheet of material disposed between the subgrade and pillow-course extending upwardly along the sides thereof and inwardly between the superstructure and pillow-course; and a sheet of material disposed between the pillow-course and superstructure overlapping the portion of the first mentioned sheet disposed between themperstructure and pillow-course, said first mentioned sheet being rebent upon itself along the inwardly and the upwardly extending portions thereof to form a double thickness wall for the said pillow-course, said overlapping sheet materials having an anchor extending through one thickness of the rebent sheet and through the other sheet into the said comminuted material of the pillow-course, said anchor having a head confined between the rebent portions of the first mentioned sheet.

17. A highway construction comprising a subgrade; a pillow-course of sand overlying the subgrade; a rigid cementitious superstructure resting upon the pillow-course; and a case for the pillow-course comprising a plurality of strips of paper extending transversely across the highway construction between the subgrade and the pillow-course in overlapped relation; and a plurality of strips of paper extending transversely across the highway construction between the pillow-course and the rigid superstructure in overlapped relation, the ends of the several strips of the first mentioned plurality of strips of paper being in overlapped relation with the ends of the several strips of the second mentioned plurality of strips of paper adjacent to the longitudinal edges of said highway construction.

18. A highway construction comprising a subgrade; a pillow-course of sand overlying the subgrade; a case for the pillow-course confining the sand to a predetermined position; a rigid cementitious superstructure resting upon the said pillow-course comprising a plurality of abutting sections; and an expansion joint formed at the abutting ends of the superstructure having a friction plate interposed between the said superstructure and the case, means for rigidly securing the plate to one section of the superstructure, and yieldable material interposed between the abutting ends of the sections, the plate extending beneath the other section and depressed into the pillow-course with its upper face in substantially the same plane as the lower faces of the superstructure sections and the upper face of the case enclosing the pillow-course.

LEO J. PEARCE. 

